New paper

ROMEO is a project that aims to research and develop novel microstructural-engineering strategies that will dramatically improve the properties of magnets based purely on light rare earth elements, especially the coercivity, which will enable them to be used for applications above 100 deg.

Abstract

The rare-earth crisis, which peaked in the summer of 2011 with the prices of both light and heavy rare earths soaring to unprecedented levels, brought about the widespread realization that the long-term availability and price stability of rare earths could not be guaranteed. This triggered a rapid response from manufacturers involved in rare earths, as well as governments and national and international funding agencies. In the case of rare-earth-containing permanent magnets, three possibilities were given quick and serious consideration: (I) increased recycling of devices containing rare earths; (II) the search for new, mineable, rare-earth resources beyond those in China; and (III) the development of high-energy-product permanent magnets with little or no rare-earth content used in their manufacture. The Replacement and Original Magnet Engineering Options (ROMEO) project addresses the latter challenge using a two-pronged approach. With its basis on work packages that include materials modeling and advanced characterization, the ROMEO project is an attempt to develop a new class of novel permanent magnets that are free of rare earths. Furthermore, the project aims to minimize rare-earth content, particularly heavy-rare-earth (HRE) content, as much as possible in Nd-Fe-B-type magnets. Success has been achieved on both fronts. In terms of new, rare-earth-free magnets, a Heusler alloy database of 236,945 compounds has been narrowed down to approximately 20 new compounds. Of these compounds, Co2MnTi is expected to be a ferromagnet with a high Curie temperature and a high magnetic moment. Regarding the reduction in the amount of rare earths, and more specifically HREs, major progress is seen in electrophoretic deposition as a method for accurately positioning the HRE on the surface prior to its diffusion into the microstructure. This locally increases the coercivity of the rather small Nd-Fe-B-type magnet, thereby substantially reducing the dependence on the HREs Dy and Tb, two of the most critical raw materials identified by the European Commission. Overall, the ROMEO project has demonstrated that rapid progress can be achieved when experts in a specific area are brought together to focus on a particular challenge. With more than half a year of the ROMEO project remaining, further progress and additional breakthroughs can be expected.

In the paper we provide a more detailed overview of the micromagnetic methods we have developed to model the thermal activation of permanent magnets. These methods allow us to simulate and understand the behaviour of permanent magnets at finite temperatures, which is important since the generators in wind turbines and electric motors in green cars operate at higher temperatures. For example, in electric cars the typical operation temperature of the motors can be around 450ºK (177º C).

Using two examples from our work with Toyota and the ROMEO project we highlight the importance of reversal mechanisms in explaining the observed performance (for example, coercivity) of the magnets.

The paper is initially published “online first” here with the permanent DOI 10.1007/s11837-015-1415-7. It can be cited as follows:

Abstract

The coercive field of permanent magnets decays with temperature. At non-zero temperatures, the system can overcome a finite energy barrier through thermal fluctuations. Using finite element micromagnetic simulations, we quantify this effect, which reduces coercivity in addition to the decrease of the coercive field associated with the temperature dependence of the anisotropy field, and validate the method through comparison with existing experimental data.

Our new paper “Thermally activated coercivity in core-shell permanent magnets” has been published today as J. Appl. Phys. 117, 17A733 (2015); http://dx.doi.org/10.1063/1.4916542 . In the paper we use numerical miromagnetics to calculate the performance of nanostructured core-shell-like permanent magnets, like the type that can now be produced by grain boundary diffusion of granular hot-deformed or sintered rare earth permanent magnets.

FIG. 3. Reversal processes in the sin- gle grain models with (i) a pure NdFeB grain, (ii) a NdFeB grain with a soft outer defect, and (iii) NdFeB core, (Dy, Nd)FeB shell and an outer soft defect. Thermally activated coercive field values are indicated with the field direction (red arrows). The saddle point image is the configuration with the highest total energy, forming the peak of the energy barrier.

Our paper titled “Micromagnetics for the coercivity of nanocomposite permanent magnets” has been published in the proceedings of the 23rd International Workshop on Rare Earth and Future Permanent Magnets and Their Applications (REPM2014). The proceedings were not made available to the public but we are providing a PDF reprint here.

The work was presented by Johann Fischbacher on 19th August 2014 in Annapolis, Maryland.

Abstract:

Exchange spring permanent magnets may be a route towards high energy product permanent magnets with low rare-earth content. In composite magnets soft magnetic phases act as nucleation sites for magnetization reversal. We use micromagnetic simulations in order to understand the role of the size and shape of the soft inclusions on the magnetization reversal. We compare the switching field of magnetically soft spheroids, cuboids and cylinders embedded in a hard magnetic matrix. Whereas there is only little difference in the switching field for enclosed spherical or cubical soft shapes, prolate inclusions enhance the stability of the magnet.